ML20246H018

Provides Addl Concerns Recently Identified Re Emergency Diesel Generators (EDG) Mfg by Tdi.Facility EDGs Only Model DSR-48 Tdi Diesels Provided W/Crankshaft Assemblies Having 11 Inch Crankpin Diameter

ML20246H018
Person / Time
Site:	Shoreham File:Long Island Lighting Company icon.png
Issue date:	11/30/1983
From:	Starostecki R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To:	Christopher R NRC OFFICE OF INVESTIGATIONS (OI)
Shared Package
ML20244D281	List: ML20244D277 ML20244D455 ML20246G961 ML20246H018 ML20246H032 ML20246H075
References
FOIA-89-192 NUDOCS 8909010063
Download: ML20246H018 (4)

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IED gg _g HI 2 01 k Docket No. 50-322 h"' ~'%7! Mig /;;;

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-MEMORANDUM FOR: Robert K. Christopher, Director, Office of Investigations FRDM: Richard W. Starostecki, Director, Division of Project and Resident Programs I

SUBJECT:

TRANSAtiERICA DELAVAL, INC. (TDI) DIESEL CONCERNS The purpose of this menorandum is to provide you with additional concerns -

recently identified relative to the Shoreham facility eraergency diesel genera-tors (EDG's) manufactured by TDI.

After the August 12, 1983_ fracture of the EDG-102 crankshaft assembly occurred during testing at Shoreham, the licensee engaged Failure Analysis Associates 3'

(FAA) to evaluate the EDG problems. LILCo and-FAA have indicated to us that the crankshaft bearings and crankpin bearings do not meet specifications. This matter was reported to us on October 14, 1983, in a telephone call from the licensee. Problems have been identified with ultimate strength, tensile elongation, and geometry (cantilevering). Apparently, about 1980, TDI upgraded this bearing material to one which met the specification. A formal 10 CFR 50.55(e) report from Long Island Lighting Company is expected shortly.

It also appears that the Shoreham EDG's are the only Model DSR-48 TDI diesels provided with crankshaft assemblies having an 11" crankpin diameter. All other DSR-48 TDI diesels reportedly were supplied with a sturdier crankshaft assembly having a 13" crankpin diameter. Preliminary FAA data indicates that {

the 11" crankpin diameter assembly fracture at Shoreham occurred due to a combination of generator and vibration loading, with high vibration loading being identified as a serious problem. It appears that tne calculational method used by TDI up until 1974 yielded nonconservative results. The values provided informally thus far indicate that good design practice calls for a crankshaft assembly torsional loading of two-thirds of the Diesel Manufactur- <

er's Association (DEMA) recommended limit of 5000 psi. Torsional testing of EDG-101 at Shoreham, after the EDG-102 crankshaft assembly fractere, reportedly showed a torsional loading of 5370 psi.

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In response to NRC concerns about the seemingly ready availability of improved TDI replacement parts for failed components (e.g., cylinder heads, rocker arm 3 holddown bchs), the licensee asked TDI for identification of product improve-ments avaibble to upgrade the diesels. The TDI response, received before crankshaft assembly fracture or identification of the out-of-specification bearings, indicated that the Shoreham EDG's were state-of-the-art. We are not I aware of any TDI notification to the licensee and/or NRC of any potential I problems because of the out-of-specification bearing materials or because of the 11" crankpin diameter crankshafts. It appears to us that a product supplied under the QA requirements imposed for EDG's should have been the subject of 10 CFR 21 notifications for such problems, and that this matter may ultimately merit referral to the FBI and/or Justice Department due to the apparent misrepresentation involved.

8909010063 890829 FE 92 PDR e -

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., Director, Office of Investigations 2 I understand that 01 will be conducting an investigation of TDI in the future. If additional information becomes available, we will provide it to you so that it can be available to the appropriate investigators.

Oraginal Signed By Richard W. Starostecki, Director -

j Division of Project and Resident Prcgrams cc:

L. G. Eisenhut, NRR R. K. Herr, RIV:01' J. Taylor, IE V. Potapous, RIV R. Caruso, NRR B. M. Bordenich, OELD d

REPORT OF INVESTIGATION REPRODUCTION INFORt1ATION l CASE NO.: 5-84-008 TITLE: TRANSAMERICA DELAVAL. INFOEv0PATrn.

SUSPECTED TALSITICATION OF OPATTTv ARcPhAvrr AND OUALITY CONTROL ff,CpRnq Total No. of Report Pages 17 TOTAL NO. OF PAGES: 112 (Including Title Page + 1 Elark Page)

(10. of Exhibit Tabs 7 No. of Exhibit Pages 08 NO. OF EXHIBIT NO. OF EXHIBIT NO. OF EXHIBIT nut'EER PAGES fil!MBER PAGES NUMBER PAGES 1 14 ,

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Miscellenecus Instructions:

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Iip6 Trennemerice Donovat Inc. .

Transamenca . .n, % ,o .. ,n Delaval ao aa ^~ l P.O. Box 2161 l Demand. Calliomia H621 k.

Date: March 15,1982 -

Tc: Training File From: R.E. Boyer

Subject:

Auditor in Training, R. Pratt Richard Pratt is designated " Auditor in Training". Mr. Pratt has had experience with Customer Audits for the last 5 years. He has attended an ASME Seminar in Quality Assurance, Sec.111.

His experience and training well qualifies Mr. Pratt as Auditor in Training.

'2 %w R.E. Boyer, Manager Quality Assurance REB /in cc: L. Mills R. Pratt Training File

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Form C 3066-3 (R 1) 1/83 - - -

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